BOILER

Kegagalan yang sering terjadi pada

industri pembangkit tenaga yang sudah
berumur
1.Kegagalan akibat fatigue
2.Kegagalan akibat korosi
3.Kegagalan akibat creep
4.Kegagalan akibat overheating
5.Kegagalan akibat erosi

Boiler Safety

KEMANAN pada BOILER

Pressure gauge & Test connection
Safety Valves (Drum & Super-heater)
Blow down valve
Drum Level Water Gauge Glasses
Stop Valve in Steam line
Stop & Check Valves in Feed Line

Safety valve

Fungsi untuk mengantisipasi tekanan dari boiler dengan

mengeluarkan steam yang berlebih ledakan bisa dihindari
1 boiler harus memiliki 1 SV, tetapi untuk boiler yang memiliki
permukaan panas lebih dari 500 sq.ft dan power input lebih dari
500 KW sebaiknya memiliki 2 atau lebih SV

Capacity of Safety valve

In any case , SV capacity must be such as to discharge all the
steam the boiler can generate without allowing pressure to
rise more than 6 % above the highest pressure at which any
valve is set & in no case more than 6 % above the maximum
allowable working pressure.
All the Safety valves used on Steam boilers must be of Direct
Spring Loaded type.

ASME markings required on

High Pressure Safety Valves:
Name or identifying trade mark of manufacturer
Manufacturers design or type number
Size in inches, Seat Diameter in inches( i.e the pipe size of
valve inlet )
Pressure in lbs/ sq.ft or Kg / sq.cm (Steam pressure at
which it is to blow)
Blow down in Kgs or lbs ( BD is the difference between the
opening & closing pressure )
Capacity in lbs / hr or kg / hr
Capacity lift in inches. It is the distance the valve disc rises
under the action of steam when the valve is blowing under a
pressure of 3 % above the set pressure.

Number of Safety Valves requirement

Each Boiler requires at least one SV, but if the heating surface exceeds 500 Sq.ft, the
boiler must have two or more Safety relief valves.
When not more than two valves of different sizes are mounted singly on the boiler,
the smaller valve must not be les than 50 % in relieving capacity of the larger valve.
Every super-heater attached to a boiler with no intervening valves between the
super-heater & boiler requires one or more safety valves on the super-heater outlet
header.With no intervening stop valves between the super-heater & boiler, the
capacity of the safety valves on the super-heater may be included in the total
required for the boiler, provided the safety valve capacity in the boiler is at least 75 %
of the aggregate SV capacity required for the Boiler.
Ex- If a boilers steaming capacity is 100 tons, a minimum of two valves are required
on Boiler with a total relieving capacity of 75 % of (100 Tons) I.e 75 tons. The
super-heater would then require a SV with a capacity of (100 75) tons
i.e 25 Tons.

Important Points
Heating Surface :
That side of the boiler surface exposed to the products of combustion,
exclusive of super-heating surface.The areas to be considered for this
purpose are tubes, fire-boxes, shells, tube sheets & the projected area
of the headers.
Sequence of Safety valves Blowing:
The super-heater safety valves should always be set at a lower
pressure than the drum safety valve ,so as to ensure steam flow
through the super-heater at all times. If the drum safety valve blows
first, the super-heater could be starved of cooling steam, leading to
possible super-heater tube overheating & rupture.

Important Points
Re-heater Safety valves :
The capacity of re-heater safety valves can not be included in the total
safety valve capacity required for the boiler & super-heater.The
relieving capacity of re-heater safety valve must not be less than 15 %
of the required total on the header. The total capacity on the re-heater
must be at least equal to the maximum steam flow for which the reheater is designed . One SV must be on the re-heater outlet.
Installation of Safety valves:
Every safety valve shall be connected so as to stand in an up-right
position with spindle vertical.